KR102559989B1 - aerosol generation - Google Patents

Abstract

Described herein is an aerosol-generating assembly comprising a heater and an aerosolizable material 103, the heater arranged to heat the aerosolizable material in use, the aerosolizable material 103 comprising at least two sections 103a, 103b having different compositions.

Description

aerosol generation

The present invention relates to aerosol generation, and in particular, but not exclusively, to aerosol generating assemblies, aerosol generating methods, aerosolizable materials for use in aerosol generation, and aerosol generating articles for use in aerosol generating assemblies.

BACKGROUND OF THE INVENTION Smoking articles such as cigarettes, cigars, and the like burn tobacco during use to produce tobacco smoke. Alternatives to these types of articles release compounds without burning.

Devices are known which typically heat an aerosolizable material to volatilize at least one component of the aerosolizable material to form an inhalable aerosol, with or without burning the aerosolizable material. Such devices are sometimes described as "heat-not-burn" devices or "tobacco heating products" (THP) or "tobacco heating devices" or the like. A variety of different arrangements for volatilizing at least one component of the aerosolizable material are known.

This material may be, for example, tobacco or other non-tobacco products, which may or may not contain nicotine, or a combination such as a blended mix.

Some known cigarette heating devices include more than one heater, each heater configured to heat different portions of the aerosolizable material when in use. This then allows different portions of the aerosolizable material to be heated at different times, providing longevity of the aerosol formation over the service life.
(Patent Document) US Patent Application Publication No. US2016/0309784 (2016.10.27.)

According to a first aspect of the present invention there is provided an aerosol-generating assembly comprising a heater and an aerosolizable material, the heater being arranged to heat an aerosolizable material in use, the aerosolizable material comprising at least two sections having different compositions.

The use of two or more sections with different compositions allows the composition of the inhaled aerosol to be selectively adjusted.

In some cases, the assembly can be configured to provide a different heat profile to each of the aerosolizable material sections having different compositions.

In some examples of aerosol-generating assemblies, the aerosolizable material has a rod shape. In some cases, at least two sections are cylindrical and are each arranged coaxially along the rod of aerosolizable material.

In some examples, the composition in the first section of aerosolizable material is poor in one or more volatile components relative to the composition in the second section. In some cases, heating of the first section of aerosolizable material may be configured to commence prior to heating of the second section.

Another example provides an aerosol-generating assembly comprising at least two heaters, the heaters being arranged to respectively heat different sections of aerosolizable material.

Another example provides an aerosol-generating assembly wherein the aerosolizable material comprises a tobacco rod, the tobacco rod comprising at least two sections having different tobacco compositions.

A second aspect of the present invention provides an aerosol-generating method comprising heating an aerosolizable material, the aerosolizable material comprising at least two sections having different compositions.

In some cases, the method provides a different thermal profile to each of the aerosolizable material sections having different compositions.

In some cases, the method includes heating an aerosolizable material having a rod shape. In some examples, at least two sections are cylindrical and arranged coaxially along the rod of aerosolizable material.

In some cases, the method includes heating the aerosolizable material, wherein a composition in the first section of the aerosolizable material is depleted in one or more volatile components compared to a composition in the second section.

In some cases, the method includes initiating heating of the first section of aerosolizable material prior to heating of the second section.

A third aspect of the present invention provides an aerosolizable material for use in an aerosol-generating assembly, the aerosolizable material comprising at least two sections having different compositions. In some cases, the aerosolizable material is or comprises a tobacco rod, wherein the tobacco rod comprises at least two sections having different tobacco compositions.

In some cases, the aerosolizable material is configured such that a section heated first in use is relatively poor in one or more volatile components compared to a section heated second in use.

A further aspect of the present invention provides an aerosol-generating article for use in an aerosol-generating assembly, the aerosol-generating article comprising the aerosolizable material according to the third aspect and a cooling element and/or filter. In some cases, a cooling element may be arranged between the aerosolizable material and the filter. In some cases, a filter may be arranged between the aerosolizable material and the cooling element.

A further aspect of the invention provides a method of making an aerosol-generating article according to the previous aspect, comprising providing an aerosolizable material having two different compositions, and wrapping the aerosolizable material and a cooling element and/or filter with a wrapper material.

Further features and advantages of the invention will become apparent from the following description of examples of the invention, given by way of example only and made with reference to the accompanying drawings.
1 is a schematic diagram of an aerosolizable material for use in an aerosol-generating assembly.
2 is a schematic diagram of an aerosol-generating article comprising an aerosolizable material for use in an aerosol-generating assembly.
3 shows a cross-sectional view of an example of an aerosol-generating article.
Figure 4 shows a perspective view of the article of Figure 3;
5 shows a cross-sectional elevational view of an example of an aerosol-generating article.
Figure 6 shows a perspective view of the article of Figure 5;
7 shows a perspective view of an example of an aerosol-generating assembly.
8 shows a cross-sectional view of an example of an aerosol-generating assembly.
9 shows a perspective view of an example of an aerosol-generating assembly.

Aerosol-generating assemblies according to examples of the invention may also be referred to herein as non-combustion heating devices, tobacco heating products or tobacco heating devices.

In some cases, the assembly is configured to provide a different thermal profile to each of the aerosolizable material sections having different compositions. This allows the flavor profile of the inhaled aerosol to be tailored. In some cases, an assembly may be configured to supply an aerosol in which the aerosol composition changes over its useful life. In other cases, the assembly may be configured such that the aerosol composition supplies a substantially uniform aerosol throughout its useful life.

In some cases, the assembly can be configured such that at least a portion of the aerosolizable material is exposed to a temperature of at least 180 °C or 200 °C for at least 50% of the heating period. In some instances, the aerosolizable material may be exposed to a thermal profile as described in co-pending application PCT/EP2017/068804, the contents of which are incorporated herein in their entirety.

In some specific cases, an assembly configured to individually heat at least two sections of aerosolizable material is provided. By controlling the temperature of the first and second sections over time so that the temperature profiles of the sections are different, it is possible to control the puff profile of the aerosol during use. Heat provided to the two portions of aerosolizable material may be provided at different times or rates; Staggering the heating in this way can allow for both rapid aerosol generation and long service life.

In one specific example, the assembly may be configured such that upon initiation of the consumption experience, the first heating element corresponding to the first section of aerosolizable material is immediately heated to a temperature of 240 °C. This first heating element is held at 240° C. for 145 seconds and then lowered to 135° C., where the temperature is maintained for the remainder of the consumption experience. 75 seconds after initiation of the consumption experience, the second heating element corresponding to the second section of aerosolizable material is heated to a temperature of 160 °C. 135 seconds after initiation of the consumption experience, the temperature of the second heating element rises to 240° C., where the temperature is maintained for the remainder of the consumption experience. The consumption experience lasts for 280 seconds, at which point both heaters cool to room temperature.

In some cases, the composition in the first section of aerosolizable material is poor in one or more volatile components compared to the composition in the second section. In particular, in some cases the assembly may be configured such that heating of the first section of aerosolizable material is initiated prior to heating of the second section. In some cases, the assembly may be configured such that heating of the first section of aerosolizable material ends prior to initiation of heating of the second section.

The inventors have established that in some known aerosol-generating assemblies in which a homogeneous aerosolizable material is used, the delivery of the components of the aerosol decreases over the lifetime of use. When only one heater is used in such prior art assemblies, the most volatile components of the aerosolizable material are rapidly consumed, and delivery of such components generally decreases puff-by-puff.

In some other known assemblies, more than one heater is used, which heaters are arranged to heat different portions of the aerosolizable material with the intention of preventing portions of the aerosolizable material from being initially heated, thereby saving volatiles in these portions for later consumption during the product's useful life. However, the inventors have determined that the bleeding of heat between different heating zones in such assemblies causes depletion of volatiles in zones where direct heating has not yet been initiated. This increases the delivery of these volatiles early in the consumption period and reduces the levels of those volatiles available for later consumption. Accordingly, the delivery of such volatile components generally decreases from puff to puff.

The inventors have established that initially heating a first section of aerosolizable material that is relatively poor in volatiles, followed by heating a second section that is relatively rich in volatiles, improves the puff profile.

In some cases, relatively constant aerosol delivery per puff is possible because delivery of volatiles during heating to the first section is augmented by heat transfer within the assembly, resulting in some consumption of volatiles from the second section.

In other cases, the increased levels of volatiles in the second section may be used to provide an aerosol in which the delivery of volatiles per puff increases over time. In such cases, and where the aerosolizable material includes tobacco, nicotine and/or tobacco flavor sensations may be stronger at the end of the smoking period. This mimics the smoking sensation of a combustible smoking article (cigarettes, cigars, etc.).

In some cases, there are two sections in the aerosolizable material. In other cases, there may be 3, 4, 5 or more sections. The composition of each section may be the same or different, provided that the composition of at least two of the sections is different. In some cases, the assembly includes a plurality of heaters arranged to each directly heat one or more sections of aerosolizable material. In some cases, the number of heaters equals the number of sections of aerosolizable material, and the heaters are arranged to each heat one section.

In some examples, the aerosolizable material may be provided as part of an aerosol-generating article that is inserted into an aerosol-generating assembly. In some cases, an aerosol-generating article may include an aerosolizable material and additionally a cooling element and/or filter. The cooling element (if present) may act or function to cool the gas or aerosol components. In some cases, the cooling element may act to cool the gaseous components to condense them to form an aerosol. The cooling element may also serve to keep very hot parts of the device away from the user. The filter (if present) may include any suitable filter known in the art, such as a cellulose acetate plug. The aerosol-generating article may be surrounded by a wrapping material such as paper.

The aerosol-generating article may further include ventilation apertures. These may be provided on the side walls of the article. In some cases, vent holes may be provided in the filter and/or cooling element. These holes allow cooling air to be drawn into the article during use, which mixes with the heated volatilized components, thereby cooling the aerosol.

Aeration enhances the generation of visible heat volatilized components from the article as the article is heated in use. The heat volatilized components are visualized by a process of cooling the heat volatilized components so that supersaturation of the heat volatilized components occurs. The heat volatilized components then undergo droplet formation, otherwise known as nucleation, and eventually the size of the aerosol particles of the heat volatilized components increases by further condensation of the heat volatilized components and coagulation of droplets newly formed from the heat volatilized components.

In some cases, the ratio of cooling air to the total amount of heated volatilized components and cooling air, known as the ventilation ratio, is at least 15%. An air permeability of 15% allows the heated volatilized components to be visualized by the above-described method. Visibility of the heated volatilized components allows the user to identify that the volatilized components have been produced, adding to the sensory experience of the smoking experience.

In another example, the air permeability is between 50% and 85% to provide additional cooling to the heated volatilized components. In some cases, the air permeability can be at least 60% or 65%.

In some cases, the aerosolizable material has a rod shape such as a cylinder. In some cases, the sections of aerosolizable material may be cylindrical and may be coaxially arranged along the rod of aerosolizable material. In some cases, the cylindrical sections may each have the same dimensions. In other cases, the cylindrical sections may have different dimensions. In some cases, the cylindrical sections may have a cross-sectional diameter of approximately 5 to 9 mm, suitably 7.5 to 8 mm. In some cases, the total length of the rod may be between about 30 and 54 mm, suitably between 36 and 48 mm. In some cases, the rod may include two sections each having a length of about 15 to 27 mm, suitably 18 to 24 mm. In some cases, the rod may include two sections each having a length of about 15 to 20 mm, suitably about 18 mm. In some cases, the rod may include two sections each having a length of about 22 to 27 mm, suitably about 24 mm.

In other cases, the sections of aerosolizable material may be in the form of prismatic sections arranged to together form a rod such as a cylinder. For example, if there are two sections, these sections may be semi-cylindrical and arranged with their respective planes in contact.

In some cases, the aerosolizable material may include between about 300 and 500 mg of tobacco. In some cases, each of the sections may hold the same amount of cigarettes. In some cases, sections may hold different amounts of cigarettes. In some cases, the aerosolizable material comprises between about 300 and 380 mg, suitably between about 330 and 350 mg of tobacco. In some cases, the aerosolizable material comprises between about 420 and 500 mg, suitably between about 450 and 470 mg of tobacco. In some cases, this material includes two sections each holding an equal amount of tobacco.

In some specific cases, the aerosolizable material has a rod shape and is formed of two cylindrical sections coaxially arranged along the rod of the aerosolizable material. In some examples, each of the cylindrical sections comprises about 150 to 190 mg, suitably about 165 to 175 mg of tobacco, and has a length of about 15 to 20 mm, suitably about 18 mm. In some other examples, each of the cylindrical sections contains about 210 to 250 mg, suitably about 225 to 235 mg of tobacco, and has a length of about 22 to 27 mm, preferably about 24 mm.

In tobacco heating products, the second heated tobacco section typically loses volatile components when the first section is heated. Thus, a tobacco rod for use with an aerosol-generating assembly described herein may be made such that the second section is enriched in volatiles relative to the first section, to account for losses of volatiles when the first section is heated.

As used herein, the term "rod" generally refers to an elongated body that may be of any shape suitable for use in an aerosol-generating assembly. In some cases, the rod is substantially cylindrical.

As disclosed above, the aerosolizable material (or at least one section thereof) may be or include a tobacco rod. The tobacco rod may include any solid material including tobacco or its derivatives. Tobacco may be any suitable solid tobacco material, such as single grades or blends, cut rag or whole leaf, ground tobacco, tobacco fiber, cut tobacco, extruded tobacco, tobacco stem and/or reconstituted tobacco. The tobacco may be of any type, including but not limited to Virginia and/or Burley and/or Oriental tobacco. In some cases, sections holding different tobacco compositions may hold different tobacco blends.

As used herein, the terms "volatiles", "volatile components" and the like may refer to any component of an inhaled aerosol, including but not limited to aerosol generating agents, flavors, tobacco flavors and aromas, water and nicotine.

Different sections of aerosolizable material may differ in content of one or more of aerosol generators, flavors, tobacco flavors and aromas, water and nicotine. In some cases, this may be achieved through the use of different tobacco blends.

As used herein, an "aerosol generating agent" is an agent that promotes generation of an aerosol upon heating. Aerosol-generating agents may promote generation of an aerosol by promoting initial evaporation and/or condensation of a gas into an inhalable solid and/or liquid aerosol. Suitable aerosol generators include polyols such as sorbitol, glycerol, and glycols such as propylene glycol or triethylene glycol; non-polyols such as monohydric alcohols, high boiling point hydrocarbons, acids such as lactic acid, glycerol derivatives, esters such as diacetin, triacetin, triethylene glycol diacetate, triethyl citrate or ethyl myristate and isopropyl myristates, including isopropyl myristate, and aliphatic carboxylic acid esters such as methyl stearate, dimethyl dodecanedioate, and dimethyl tetradecanedioate.

As used herein, the terms "flavour" and "flavourant" refer to ingredients that, when permitted by local regulations, can be used to create a desired taste or aroma in a product for adult consumers. These include extracts (e.g. licorice, hydrangea, Japanese white bark magnolia leaf, chamomile, fenugreek, clove, menthol, Japanese mint, aniseed, cinnamon, herbs, wintergreen, cherry, berry, peach, apple, Drambuie, bourbon, scotch, whiskey, spearmint, peppermint, lavender, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium ium), honey essence, rose oil, vanilla, lemon oil, orange oil, cassia, caraway, cognac, jasmine, ylang-ylang, sage, fennel, allspice, ginger, anise, coriander, coffee, or mint oil from any species of the genus Mentha), flavor enhancers, bitterness receptor site blockers, sensory receptor site activators or stimulators, sugars and/or sugar substitutes (e.g. sucralose, acesulfame potassium, aspartame) ame), saccharine, cyclamates, lactose, sucrose, glucose, fructose, sorbitol or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals or breath freshening agents. can These may be man-made, synthetic or natural ingredients or blends thereof. They may be in any suitable form, for example oils, liquids or powders.

In use, in some cases, an aerosol-generating article may be arranged in an aerosol-generating device that heats the article to generate an aerosol without burning. In some other cases, the article may be provided in an assembly with a fuel source such as a combustible fuel source or a chemical heat source that heats the aerosolizable material without burning it.

In some cases, the heater provided within the aerosol-generating assembly may be a thin film electrically resistive heater. In other cases, the heater may include an induction heater or the like. If more than one heater is present, each heater may be the same or different.

Typically, the or each heater is connected to a battery, which may be a rechargeable battery or a non-rechargeable battery. Examples of suitable batteries include, for example, lithium-ion batteries, nickel batteries (eg, nickel-cadmium batteries), alkaline batteries, and the like. The battery is electrically coupled to the heater and controllable through appropriate circuitry to supply power when needed to heat the aerosolizable material (to volatilize components of the aerosolizable material without burning the aerosolizable material).

In one example, the heater is generally in the form of a hollow cylindrical tube having a hollow internal heating chamber into which an aerosolizable material is inserted for heating in use. Different arrangements for the heater are possible. For example, the heater may be formed as a single heater, or may be formed of a plurality of heaters aligned along the longitudinal axis of the heater. (For simplicity, references herein to a “heater” should be taken to include a plurality of heaters, unless the context requires otherwise.) The heater may be annular or tubular. The heater may be dimensioned such that when inserted substantially all of the aerosolizable material is positioned within the heating element(s) of the heater such that substantially all of the aerosolizable material is heated in use. The heaters may be arranged such that selected regions of the aerosolizable material may be heated independently, for example in sequence (sequentially) or together (simultaneously) as desired.

The heater may be surrounded along at least a portion of its length by a thermal insulator that helps reduce heat passing from the heater to the exterior of the aerosol-generating assembly. This helps to curb the power requirement for the heater, as it generally reduces heat losses. Insulation also helps keep the exterior of the aerosol-generating assembly cool during operation of the heater.

Features described in connection with one aspect of the invention are, to the extent compatible, explicitly disclosed in combination with other aspects and examples described herein.

1 schematically illustrates an example of an aerosolizable material for use with an aerosol-generating assembly. The aerosolizable material is in the form of a cylindrical rod and comprises a first section 103a and a second section 103b. In this example, the second section 103b is farther from the mouth than the first section 103a in use.

The two sections 103a, 103b have different compositions. In one example, the second section 103b is rich in volatile components compared to the first section 103a. In this case, the first section 103a (closer to the mouth end of the assembly) is first heated in use. In another example, the second section 103b is poorer in volatile components than the first section 103a, in which case the second section (distant from the mouth end of the aerosol-generating article 101) is first heated in use.

2 schematically illustrates one example of an aerosol-generating article 101 for use with an aerosol-generating assembly. The aerosol-generating article 101 includes a cylindrical rod of aerosolizable material 103 illustrated in FIG. 1 , a cooling element 107 , a filter 109 and a mouth end segment 111 . Cooling element 107 and filter 109, as illustrated, may be arranged between the mouth end and mouth end segment 111 of aerosolizable material 103 such that the flow from aerosolizable material 103 passes through cooling element 107 and filter 109 before reaching the user (or vice versa if the filter is arranged before the cooling element in the flow, conversely) ). 2 illustrates cooling element 107, filter 109 and mouth end segment 111, in other examples one or more of these elements may be omitted.

In some examples, the mouth end segment 111 (if present) may be formed of, for example, paper, such as in the form of a spirally wound paper tube, cellulose acetate, cardboard, crimped paper, such as crimped heat-resistant paper or crimped parchment paper, and/or polymeric materials, such as low density polyethylene (LDPE), or some other suitable material. Mouth end segment 111 may comprise a hollow tube. Such a hollow tube may provide a filtering function to filter out volatilized aerosolizable material. The mouth end segment 111 may be elongated, spaced from the very hot portion(s) of a main device (not shown) that heats the aerosolizable material.

In some examples, filter 109 (if present) may be a filter plug and may be made of cellulose acetate, for example.

In some cases, the cooling element 107 (if present) can include a monolithic rod having first and second ends and including a plurality of through holes extending between the first and second ends. The through holes may extend substantially parallel to the central longitudinal axis of the rod. The through-holes of the cooling element 107 can be arranged generally in the radial direction of the element when viewed in cross section. That is, in one example, the element defines through holes and has inner walls with two main components, radial walls and central walls. The radial walls extend along the radii of the cross section of the element, and the central walls are centered at the center of the cross section of the element. In one example, the central walls are circular, but other regular or irregular cross-sectional shapes may be used. Likewise, in one example, the cross-section of the element is circular, but other regular or irregular cross-sectional shapes may be used.

In one example, most of the through holes have a hexagonal or generally hexagonal cross-sectional shape. In this example, the element may be referred to as a "honeycomb" structure when viewed from one end.

In some cases, the cooling element 107 may include a hollow tube that separates the filter 109 (if present) from the very hot portion(s) of the main apparatus that heats the aerosolizable material. Cooling element 107 may be formed, for example, of paper, cellulose acetate, cardboard, crimped paper, such as crimped heat resistant paper or crimped parchment, and/or polymeric materials, such as low density polyethylene (LDPE), or some other suitable material, such as in the form of a spirally wound paper tube.

Cooling element 107 (if present) may be substantially incompressible. The cooling element may be formed of a ceramic material, or a polymer, which may be an extrudable plastic material, for example a thermoplastic polymer. In one example, the porosity of the element is in the range of 60% to 75%. Porosity in this sense can be a measure of the percentage of the cross-sectional area of an element occupied by through holes. In one example, the porosity of the element is between about 69% and 70%.

Other examples of cooling elements are disclosed in PCT/GB2015/051253, the entire contents of which, especially the description of FIGS. 1 to 8 and page 8, line 11 to page 18, line 16, are hereby expressly incorporated by reference.

In further examples, cooling element 107 may be formed from sheet material that is folded, crimped or corrugated to form through holes. The sheet material may be, for example, a metal such as aluminum; polymeric plastic materials such as polyethylene, polypropylene, polyethylene terephthalate or polyvinyl chloride; or made of paper.

In some examples, cooling element 107 and filter 109 may be held together by a wrapper paper (not shown) to form an assembly. The assembly may then be joined to the aerosolizable material by an additional wrapper (not shown) surrounding the assembly and at least the mouth end of the aerosolizable material to form an aerosol-generating article 101 . In other examples, the aerosol-generating article 101 is formed by effectively wrapping the cooling element 107, filter 109, and aerosolizable material 103 in one operation, and the cooling element and/or filter components (if present) are not provided with separate tipping paper.

Referring now to FIGS. 3 and 4 , partial cut-away cross-sectional and perspective views of one example of an aerosol-generating article 201 are shown. Article 201 is adapted for use with a device having a power source and heater. The article 201 of this embodiment is particularly suitable for use with the device 1 shown in FIGS. 7 to 9 described below. In use, article 201 can be removably inserted into the device shown in FIG. 7 at insertion point 20 of device 1 .

An example article 201 is in the form of a substantially cylindrical rod comprising a body of aerosolizable material 203 and a filter assembly 205 in the form of a rod. The aerosolizable material has two sections 203a, 203b with different compositions. In some cases, two sections 203a, 203b of aerosolizable material 203 may be joined together by an annular tipping paper (not shown) positioned substantially around the circumference of aerosolizable material 203.

Filter assembly 205 includes three segments: cooling segment 207 , filter segment 209 and mouth end segment 211 . The article 201 has a first end 213, also known as a mouth end or proximal end, and a second end 215, also known as a distal end. The body of aerosolizable material 203 is positioned towards the distal end 215 of the article 201 . In one example, the cooling segment 207 is positioned adjacent the body of the aerosolizable material 203 between the body of the aerosolizable material 203 and the filter segment 209 such that the cooling segment 207 is in contact with the aerosolizable material 203 and the filter segment 209. In other examples, there may be a separation between the body of aerosolizable material 203 and cooling segment 207 and between the body of aerosolizable material 203 and filter segment 209 . A filter segment 209 is positioned between the cooling segment 207 and the mouth end segment 211 . The mouth end segment 211 is positioned towards the proximal end 213 of the article 201 , adjacent to the filter segment 209 . In one example, filter segment 209 is in contact with mouth end segment 211 . In one embodiment, the total length of the filter assembly 205 is between 37 mm and 45 mm, suitably 41 mm.

In one embodiment, each of the sections of aerosolizable material 203 includes tobacco. However, in other respective embodiments, the sections of aerosolizable material 203 may consist of tobacco, may consist substantially entirely of tobacco, may include tobacco and an aerosolizable material other than tobacco, may include an aerosolizable material other than tobacco, or may be free of tobacco. The aerosolizable material may include an aerosol former, such as glycerol, and/or a flavoring agent.

In some examples, the body of aerosolizable material 203 is between 30 mm and 54 mm long, suitably between 36 mm and 48 mm long. The sections of aerosolizable material may be the same length as each other (ie half the total length in embodiments having two sections of aerosolizable material 203).

In one example, the total length of the article 201 is between 71 mm and 95 mm, suitably between 79 mm and 87 mm, suitably about 83 mm.

The axial end of the body of aerosolizable material 203 is visible at the distal end 215 of the article 201 . However, in other embodiments, the distal end 215 of the article 201 may include an end member (not shown) covering the axial end of the body of the aerosolizable material 203 .

The body of aerosolizable material 203 is coupled to filter assembly 205 by an annular tipping paper (not shown) positioned substantially around the circumference of filter assembly 205 so as to surround filter assembly 205 and extending partially along the length of the body of aerosolizable material 203. In one example, the tipping paper is made from 58GSM standard tipping base paper. In one example, the tipping paper has a length of 42 mm to 50 mm, suitably about 46 mm.

In some cases, the same tipping paper may be used to join sections 203a, 203b of aerosolizable material 203 and filter assembly 205.

In one example, the cooling segment 207 is an annular tube and is positioned around an air gap to define an air gap within the cooling segment. The air gap provides a chamber through which heated volatilized components originating from the body of aerosolizable material 203 flow. Cooling segment 207 is hollow to provide a chamber for aerosol accumulation, but has sufficient stiffness to withstand axial compressive forces and bending moments that may occur during manufacture and while article 201 is being inserted into device 1 in use. In one example, the thickness of the wall of the cooling segment 207 is approximately 0.29 mm.

The cooling segment 207 provides physical displacement between the aerosolizable material 203 and the filter segment 209. The physical displacement provided by the cooling segment 207 will provide a thermal gradient across the length of the cooling segment 207 . In one example, the cooling segment 207 is configured to provide a temperature difference of at least 40 °C between the heated volatilized component entering the first end of the cooling segment 207 and the heated volatilized component exiting the second end of the cooling segment 207. In one example, the cooling segment 207 is configured to provide a temperature difference of at least 60 °C between the heated volatilized component entering the first end of the cooling segment 207 and the heated volatilized component exiting the second end of the cooling segment 207. This temperature differential over the length of the cooling element 207 protects the temperature sensitive filter segment 209 from the high temperatures of the aerosolizable material 203 when the aerosolizable material 203 is heated by the heating arrangement of the device 1. If no physical displacement is provided between the filter segment 209 and the body of aerosolizable material 203 and the heating elements of device 1, the temperature sensitive filter segment 209 will be damaged in use, and will therefore not effectively perform its required functions.

In one example, the length of the cooling segment 207 is at least 15 mm. In one example, the length of the cooling segment 207 is between 20 mm and 30 mm, suitably between 23 mm and 27 mm, or between 25 mm and 27 mm, most suitably about 25 mm.

The cooling segment 207 may be made of paper, which means that the cooling segment 207 comprises a material that does not generate compounds of interest, e.g. toxic compounds, when in use adjacent to the heater arrangement of the device 1. In one example, the cooling segment 207 is made of a spirally wound paper tube that provides a hollow inner chamber but retains mechanical strength. Spiral wound paper tubes can meet the stringent dimensional precision requirements of high speed manufacturing processes with respect to tube length, outer diameter, roundness and straightness.

In another example, the cooling segment 207 is a recess created from stiff plug wrap or tipping paper. Rigid plug wrap or tipping paper is made to be rigid enough to withstand axial compressive forces and bending moments that may occur during manufacture and while article 201 is being inserted into device 1 in use.

Filter segment 209 may be formed of any filter material sufficient to remove one or more volatilized compounds from heat volatilized components from the aerosolizable material. In one example, filter segment 209 is made of a mono-acetate material such as cellulose acetate. The filter segment 209 provides cooling and irritation-reduction from the heated volatilized components without depleting the amount of the heated volatilized components to a level unsatisfactory to the user.

The density of the cellulose acetate tow material of the filter segment 209 controls the pressure drop across the filter segment 209, which in turn controls the resistance to draw of the article 1. Accordingly, the material selection of the filter segment 209 is important in controlling the resistance to draw of the article 201. Additionally, the filter segments perform a filtration function in article 201 .

In one example, the filter segment 209 is made of 8Y15 grade filter tow material, which provides a filtering effect on the hot volatilized material while also reducing the size of condensed aerosol droplets resulting from the hot volatilized material, which in turn reduces the irritation and throat impact of the hot volatilized material to satisfactory levels.

The presence of the filter segment 209 provides an insulating effect by providing additional cooling to the heated volatilized components exiting the cooling segment 207. This additional cooling effect reduces the contact temperature of the user's lips on the surface of filter segment 209 .

One or more flavors may be added to filter segment 209 in the form of injecting flavored liquids directly into filter segment 209, or by embedding or arranging one or more flavored breakable capsules or other flavor carriers within the cellulose acetate tow of filter segment 209.

In one example, filter segment 209 is between 6 mm and 10 mm long, suitably about 8 mm.

The mouth end segment 211 is an annular tube and is positioned around the air gap to define an air gap within the mouth end segment 211 . The air gap provides a chamber for the heated volatilized components to flow out of the filter segment 209. Mouth end segment 211 is hollow to provide a chamber for aerosol accumulation, but has sufficient stiffness to withstand axial compressive forces and bending moments that may occur during manufacture and while the article is being inserted into device 1 in use. In one example, the thickness of the wall of the mouth end segment 211 is approximately 0.29 mm.

In one example, the length of the mouth end segment 211 is between 6 mm and 10 mm, suitably about 8 mm.

Mouth end segment 211 may be made of a spirally wound paper tube that provides a hollow internal chamber but retains critical mechanical stiffness. Spiral wound paper tubes can meet the stringent dimensional precision requirements of high-speed manufacturing processes with respect to tube length, outer diameter, roundness and straightness.

The mouth end segment 211 serves to prevent any liquid condensate that has accumulated at the outlet of the filter segment 209 from coming into direct contact with the user.

In one example, it should be understood that mouth end segment 211 and cooling segment 207 may be formed from a single tube, and filter segment 209 is positioned within that tube separating mouth end segment 211 and cooling segment 207.

Referring now to FIGS. 5 and 6 , there are shown partial cutaway cross-sectional and perspective views of an example of an article 301 in accordance with one embodiment of the present invention. The reference numerals shown in FIGS. 5 and 6 are equivalent to the reference numerals shown in FIGS. 3 and 4 , but in increments of 100.

In the example of article 301 shown in FIGS. 5 and 6 , article 301 is provided with a vent area 317 to allow air to flow from the outside of article 301 to the inside of article 301 . In one example, ventilation area 317 takes the form of one or more ventilation holes 317 formed through the outer layer of article 301 . Vent holes may be located in the cooling segment 307 to aid in cooling the article 301 . In one example, vent region 317 includes one or more rows of holes, and in some cases, each row of holes is arranged circumferentially around article 301 in a cross-section substantially perpendicular to the longitudinal axis of article 301.

In one example, there are one to four rows of ventilation holes to provide ventilation for the article 301 . Each row of ventilation holes may have 12 to 36 ventilation holes 317 . The ventilation holes 317 may be, for example, 100 to 500 μm in diameter. In one example, the axial spacing between rows of vent holes 317 is between 0.25 mm and 0.75 mm, suitably 0.5 mm.

In one example, the vent holes 317 are uniformly sized. In another example, the vent holes 317 vary in size. Vent holes can be made using any suitable technique, for example one or more of the following techniques: laser technology, mechanical drilling of cooling segment 307, or pre-drilling of cooling segment 307 before cooling segment 307 is formed into article 301. Vent holes 317 are positioned to provide effective cooling to article 301 .

In one example, the rows of vent holes 317 are located at least 11 mm from the proximal end 313 of the article, suitably located 17 mm to 20 mm from the proximal end 313 of the article 301 . The location of the ventilation holes 317 is positioned such that a user does not block the ventilation holes 317 when the article 301 is in use.

Providing the rows of vent holes 17 mm to 20 mm from the proximal end 313 of the article 301 allows the vent holes 317 to be located outside of the device 1 when the article 301 is fully inserted into the device 1, as can be seen in FIGS. 8 and 9 . By placing the vent holes on the outside of the device, unheated air can enter the article 301 from outside the device 1 through the vent holes to help cool the article 301 .

The length of the cooling segment 307 allows the cooling segment 307 to be partially inserted into the device 1 when the article 301 is fully inserted into the device 1 . The length of the cooling segment 307 serves the first function of providing a physical gap between the heater arrangement and the heat sensitive filter arrangement 309 of the device 1, and the second function of allowing the vent holes 317 to be located in the cooling segment while also being positioned outside of the device 1 when the article 301 is fully inserted into the device 1. As can be seen in FIGS. 8 and 9 , most of the cooling element 307 is located within the device 1 . However, there is a portion of the cooling element 307 that extends out of the device 1 . Ventilation holes 317 are located in this part of the cooling element 307 that extends out of the device 1 .

Referring now to FIGS. 7-9 in more detail, there is shown an example of a device 1 arranged to heat an aerosolizable material to volatilize at least one component of the aerosolizable material, thereby forming an aerosol that can typically be inhaled. The device 1 is a heating device 1 that releases compounds by heating the aerosolizable material without burning it.

The first end 3 is sometimes referred to herein as the mouth end or proximal end 3 of the device 1 , and the second end 5 is sometimes referred to herein as the distal end 5 of the device 1 . The device 1 has an on/off button 7 which allows the entire device 1 to be switched on/off according to the user's desire.

The device 1 includes a housing 9 for positioning and protecting the various internal components of the device 1 . In the illustrated example, the housing 9 comprises a uni-body sleeve 11 that surrounds the circumference of the device 1, which sleeve 11 is covered with a top panel 17, which generally defines the 'top' of the device 1, and a bottom panel 19, which generally defines the 'bottom' of the device 1. In another example, the housing includes a front panel, a back panel and a pair of opposing side panels, in addition to a top panel 17 and a bottom panel 19 .

Top panel 17 and/or bottom panel 19 may be removably secured to integral sleeve 11 to allow easy access to the interior of device 1, or may be “permanently” secured to integral sleeve 11, for example to deter a user from accessing the interior of device 1. In one example, panels 17 and 19 are made of a plastic material, including, for example, glass-filled nylon formed by injection molding, and integral sleeve 11 is made of aluminum, although other materials and other manufacturing processes may be used.

The top panel 17 of the device 1 has an opening 20 at the mouth end 3 of the device 1 through which, in use, an article 201, 301 comprising an aerosolizable material may be inserted into and removed from the device 1 by a user.

Within the housing 9 a heater arrangement 23, a control circuit 25 and a power supply 27 are positioned or fixed. In this example, heater arrangement 23, control circuit 25, and power supply 27 are laterally adjacent (i.e., as viewed from the end), and control circuit 25 is generally located between heater arrangement 23 and power supply 27, although other locations are possible.

Control circuitry 25 may include a controller, such as a microprocessor arrangement, constructed and arranged to control heating of the aerosolizable material within consumable articles 201, 301, as discussed further below.

The power source 27 can be, for example, a battery, which can be a rechargeable battery or a non-rechargeable battery. Examples of suitable batteries include, for example, lithium-ion batteries, nickel batteries (eg, nickel-cadmium batteries), alkaline batteries, and the like. A battery 27 is electrically coupled to the heater arrangement 23 to supply power when needed and under the control of a control circuit 25 to heat the aerosolizable material in the article (volatilizing the aerosolizable material without burning it, as discussed).

An advantage of locating the power source 27 laterally adjacent to the heater arrangement 23 is that a physically large power source 25 can be used without making the entire device 1 too long. As will be appreciated, a physically large power source 25 generally has a higher capacity (i.e., the total electrical energy that can be supplied, often measured in ampere-hours or the like), and thus the battery life of device 1 may be longer.

In one example, the heater arrangement 23 is generally in the form of a hollow cylindrical tube having a hollow internal heating chamber 29 into which an article 201 , 301 comprising an aerosolizable material is inserted for heating in use. Different arrangements for the heater arrangement 23 are possible. For example, the heater arrangement 23 may include a single heating element or may be formed of a plurality of heating elements aligned along the longitudinal axis of the heater arrangement 23 . The or each heating element may be annular or tubular, or at least part-annular or part-tubular around its circumference. In one example, the or each heating element may be a thin film heater. In another example, the or each heating element may be made of a ceramic material. Examples of suitable ceramic materials include alumina and aluminum nitride and silicon nitride ceramics that can be laminated and sintered. Other heating arrangements are possible, including, for example, induction heating, infrared heater elements that heat by emitting infrared radiation, or resistive heating elements formed, for example, by resistive electrical windings.

In one specific example, the heater arrangement 23 is supported by a stainless steel support tube and includes a polyimide heating element. The heater arrangement 23 is dimensioned such that when the article 201, 301 is inserted into the device 1, substantially the entire body of the aerosolizable material 203, 303 of the article 201, 301 is inserted into the heater arrangement 23.

The or each heating element may be arranged such that selected regions of the aerosolizable material may be heated independently, for example in sequence (sequentially) or together (simultaneously) as desired.

In this example, the heater arrangement 23 is surrounded along at least part of its length by an insulating material 31 . Insulation 31 helps reduce heat passing from heater arrangement 23 to the outside of device 1 . This helps to contain the power requirement for the heater arrangement 23 as it generally reduces heat losses. In addition, the insulator 31 helps to keep the exterior of the device 1 at a low temperature during operation of the heater arrangement 23 . In one example, the insulation 31 may be a double wall sleeve providing a low pressure region between the two walls of the sleeve. That is, the insulation 31 may be, for example, a “vacuum” tube, i.e. a tube that is at least partially evacuated to minimize heat transfer by conduction and/or convection. Other arrangements for the insulation 31 are possible, including the use of insulation materials, including, for example, suitable foam-type materials, in addition to or instead of a double wall sleeve.

The housing 9 may further include various internal support structures 37 for supporting the heater arrangement 23 as well as all internal components.

The device 1 further comprises a collar 33 extending around the opening 20 and protruding from the opening 20 into the interior of the housing 9, and a generally tubular chamber 35 positioned between the collar 33 and one end of the vacuum sleeve 31. The chamber 35 further includes a cooling structure 35f, in this example, the cooling structure 35f includes a plurality of cooling fins 35f spaced along an exterior surface of the chamber 35 and each arranged circumferentially around the exterior surface of the chamber 35. When the article 201, 301 is inserted into the device 1 over at least a portion of the length of the hollow chamber 35, an air gap 36 exists between the hollow chamber 35 and the article 201, 301. Air gap 36 is around all of the circumference of articles 201 , 301 over at least a portion of cooling segment 307 .

The collar 33 includes a plurality of ridges 60 arranged circumferentially around the periphery of the opening 20 and protruding into the opening 20 . Ridges 60 occupy space within opening 20 such that the open span of opening 20 at locations of ridges 60 is less than the open span of opening 20 at locations without ridges 60. Ridges 60 are configured to engage an article 201 , 301 inserted into the device 1 to help secure the article 201 , 301 within the device 1 . The open spaces (not shown in the figures) defined by the article 201 , 301 and adjacent pairs of ridges 60 form ventilation paths around the exterior of the article 201 , 301 . These ventilation paths allow hot vapors escaping from the articles 201, 301 to exit the device 1, and cool air to flow into the device 1 around the articles 201, 301 in the air gap 36.

In operation, articles 201 , 301 are removably inserted into insertion point 20 of device 1 , as shown in FIGS. 7-9 . Referring specifically to FIG. 8 , in one example, the body of the aerosolizable material 203, 303 positioned towards the distal end 215, 315 of the article 201, 301 is completely contained within the heater arrangement 23 of the device 1. Proximal ends 213 , 313 of articles 201 , 301 extend from device 1 and serve as a mouthpiece assembly for a user.

In operation, the heater arrangement 23 will heat the consumable article 201 , 301 to volatilize at least one component of the aerosolizable material from the body of the aerosolizable material 203 , 303 .

The primary flow path for the heated volatilized components from the body of aerosolizable material 203, 303 is axially through the article 201, 301, through the chamber inside the cooling segment 207, 307, through the filter segment 209, 309, through the mouth end segment 211, 313 to the user. In one example, the temperature of the heated volatilized components generated from the body of aerosolizable material is between 60° C. and 250° C., which may be higher than the user acceptable inhalation temperature. The heated volatilized components are cooled as they move through the cooling segments 207 and 307, and some of the volatilized components will condense on the inner surfaces of the cooling segments 207 and 307.

In the examples of article 301 shown in FIGS. 5 and 6 , cooling air may enter cooling segment 307 through vent holes 317 formed in cooling segment 307 . This cooling air will mix with the heated volatilized components to provide additional cooling to the heated volatilized components.

The above examples should be understood as illustrative examples of the present invention. It should be understood that any feature described in connection with any one example may be used alone or in combination with other features described, and may also be used in combination with one or more features of any other example or any combination of any other examples. Equivalents and variations not described above may also be used without departing from the scope of the invention as defined in the appended claims.

Claims (19)

An aerosol generating assembly comprising a heater and an aerosolizable material, comprising:
wherein the heater is arranged to heat the aerosolizable material in use, the aerosolizable material comprising a tobacco rod, the tobacco rod comprising at least two sections having different tobacco compositions, wherein a composition in a first section of aerosolizable material is lower in one or more volatile components than a composition in a second section, wherein heating of the first section of aerosolizable material is initiated prior to heating of the second section;
An aerosol-generating assembly comprising a heater and an aerosolizable material. According to claim 1,
wherein the assembly is configured to provide a different heat profile to each of the sections of the aerosolizable material having different compositions.
An aerosol-generating assembly comprising a heater and an aerosolizable material. According to claim 1 or 2,
The aerosolizable material has a rod shape,
An aerosol-generating assembly comprising a heater and an aerosolizable material. According to claim 3,
wherein the at least two sections are cylindrical and each of the sections is arranged coaxially along the rod of aerosolizable material.
An aerosol-generating assembly comprising a heater and an aerosolizable material. According to claim 1 or 2,
comprising at least two heaters, the heaters being arranged to respectively heat different sections of the aerosolizable material;
An aerosol-generating assembly comprising a heater and an aerosolizable material. As a method of generating an aerosol,
heating an aerosolizable material in an aerosol-generating assembly, the aerosolizable material comprising a tobacco rod, the tobacco rod comprising at least two sections having different tobacco compositions, a composition in a first section of aerosolizable material having a lower one or more volatile components than a composition in a second section, wherein heating of the first section of aerosolizable material is initiated prior to heating of the second section;
A method of generating an aerosol. According to claim 6,
Each of the sections of the aerosolizable material having different compositions is provided with a different thermal profile.
A method of generating an aerosol. According to claim 6 or 7,
The aerosolizable material has a rod shape,
A method of generating an aerosol. According to claim 8,
wherein the at least two sections are cylindrical and arranged coaxially along the rod of aerosolizable material.
A method of generating an aerosol. As an aerosolizable material for use in an aerosol-generating assembly,
wherein the aerosolizable material comprises a tobacco rod, the tobacco rod comprising at least two sections having different tobacco compositions, wherein a composition in a first section of aerosolizable material is lower in one or more volatile components than a composition in a second section, wherein heating of the first section of aerosolizable material is initiated prior to heating of the second section;
Aerosolizable materials for use in aerosol-generating assemblies. An aerosol generating article for use in an aerosol generating assembly comprising:
an aerosolizable material according to claim 10; and
Including at least one of a cooling element or filter,
An aerosol-generating article for use in an aerosol-generating assembly. A method of manufacturing an aerosol-generating article according to claim 11 comprising:
providing an aerosolizable material having two different compositions; and
wrapping at least one of the aerosolizable material and the cooling element or filter with a wrapper material.
A method of making an aerosol-generating article. delete delete delete delete delete delete delete